Illuminated vehicle interior assembly such as a safety belt buckle assembly

ABSTRACT

An illuminable vehicle interior assembly such as safety belt buckle assembly is provided. An illumination module includes a substrate, a light source supported on the substrate to emit incoherent visible light rays through a light emitting surface of the light source and a driver supported on the substrate to controllably supply electrical power to the light source based on a command signal from a remote electronic control unit over a vehicle bus. A lens is molded in a molding process to have a light transmissive output surface and a light transmissive input surface aligned with the light source. The lens gathers and receives the light rays at the input surface and redirects gathered light rays to the output surface to generate light in a pattern of substantially uniform intensity into a passenger compartment of a vehicle.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. patentapplication Ser. Nos. 15/637,054 and 15/677,517, both filed on Jun. 29,2017. This application is related to U.S. Patent application entitled“Illuminator Assembly for a Safety Belt Buckle” Ser. No. 15/784,378,filed on the same day as this application.

TECHNICAL FIELD

This invention generally relates to illumination of conventional safetybelt buckles and, in particular, to assemblies for use with suchbuckles.

BACKGROUND

As described in U.S. Pat. No. 6,676,472, generally, there are twodistinct types of lighting applications. In one, direction of the lightrays is relatively unimportant. In the other, light rays must bedirected in a particular manner subsequent to their generation. Withrespect to automotive lighting, after light rays are generated by alamp, they must by focused/dispersed according to somewhat exactingstandards. The requirements for light-directed lamps, such asheadlights, sidemarkers, tail lights, brake lights, directional,hazards, CHMSLs (Center, high-mounted, stop slights), differ. However,they all share the characteristic that their light rays need to bedirected in some specific manner.

Lamp elements generate light rays and lenses and/or reflecting elementsdirect the light rays. Lamp elements generally fall into threecategories: light-emitting diode (LED), incandescent and discharge.

Discharge lamps are generally characterized as having a sealed envelopfilled with a gas, the atoms/ions of which, when properly excited, giveoff light rays. Lens elements may be categorized as refractive, Fresnel,or Total Interal Reflection (TIR). TIR lenses have the ability to gatherlight rays from large solid angles and redirect them efficiently.

Interior lighting systems for automotive and other vehicle applicationsare generally used for two purposes. One is to provide general areaillumination and the other is feature lighting of specific objects,either for aesthetic or functional reasons. Traditionally, theseinterior lighting systems have utilized incandescent lamps for both areaand feature lighting, often using lenses to control the shape and lightintensity distribution of the emitted light rays. Although incandescentlamp systems can often be integrated into various vehicle interior trimcomponents in a simple manner, various considerations do arise whichcomplicate their use for automotive lighting. For example, where heatfrom the lamp could damage adjacent components or otherwise causeproblems, thermal management of that heat must be implemented. Also,there is often little room in or behind a particular vehicle interiorbody panel or trim component for the lamp, its socket, and lensing.

More recently, distributed light systems have found use in vehicles.These may use fiber optics or other means to deliver the light rays to adesired location. The use of a lens and focusing or dispersing devicesmay be employed to direct the light rays. It is well known that lighttransparent members including for example rods, panels, films, sheetsand plates, can be made into light emitting members or illuminators bygrooving or notching the members in a certain pattern.

Fiber optic substrates can be made into illuminators by marring orabrading the surface of the optical fibers at various points along theirlength to cause a portion of the light entering one or both ends of theoptical fibers to be emitted from the marred surface areas.

Increased surface marring results in increased light emission.Accordingly, the intensity of the light emitted along the length of thesubstrates can be varied by varying the density or aggressiveness of thesurface marring.

Such areas as foot wells, door handles, seats, trucks, cargo areas,dashboards, door sills, headliners, grab handles, etc. may beilluminated using a wide combination of technologies. In addition toincandescent lights and fluorescent lighting, LED illumination, coldcathode technology, and electroluminescent technology may now find use.

Under 49 C.F.R. Part 571.101 (FMVSS 101) 5.53 Illumination, 55.3.4Brightness of interior lamps.

-   -   (a) Any source of illumination within the passenger compartment        which is forward of a transverse vertical plane 110 mm rearward        of the manikin “H” point with the driver's seat in its rearmost        driving position, which is not used for the controls and        displays regulated by this standard, which is not a telltale,        and which is capable of being illuminated while the vehicle is        in motion, shall have either:        -   (1) Light intensity which is manually or automatically            adjustable to provide at least two levels of brightness;        -   (2) A single intensity that is barely discernible to a            driver who has adapted to dark ambient roadway conditions;            or        -   (3) A means of being turned off.

One practice in the automotive industry is utilization of all-plastic,fabricated parts, such as, but not limited to, instrument panels,interior trims, and door panels. It is known in other automotive partsareas that different, aesthetically pleasing outer class A surfacesenhance the overall appearance of the interior of automotive vehicles.

The following patent documents are related to the present invention: UKPatent Application GB 2492100A; U.S. Pat. Nos. 5,005,108; 5,549,323;5,542,694; 5,558,364; 5,895,115; 6,062,595; 6,053,526; 6,158,867;6,193,399; 6,464,381; 6,594,417; 6,652,128; 6,676,472; 6,974,238;7,150,550; 7,201,588; 7,237,933; 7,299,892; 7,387,397; 7,441,801;7,866,858; 7,987,030; 8,016,465; 8,061,861; 8,075,173; 8,162,519;8,210,564; 8,215,810; 8,235,567; 8,256,945; 8,408,627; 8,408,766;8,425,062; 8,449,161; 8,469,562; 8,596,803; 8,627,586; 8,816,586;8,925,959; 8,067,556; 9,446,734, 9,376,055; and 9,481,296; and U.S.Published Applications 2003/0209889; 2009/0021459; 2009/0251917;2010/0104780; 2010/0194080; 2011/0002138; 2012/0188779; 2012/0217767;2013/0279188; 2013/0329447; 2014/0077531; and 2015/0307033.

U.S. published application 2013/0329447 discloses a lighting assemblycomprising an optical fiber light guide panel member having a lightconducting core cladded on opposite sides by cladding made of opticallytransparent material having a lower index of refraction than the lightconducting core to cause total internal reflection of conducted lightwithin the light conducting core at the core-cladding interface.Disruptions at one or more areas of the cladding cause conducted lightwithin the light conducting core to be emitted from one or more areas ofthe panel member. Electrical circuitry is bonded to one or both sides ofthe cladding. One or more LEDs embedded in the panel member areelectrically coupled to the electrical circuitry and optically coupledto the light conducting core.

Polymethyl methacrylate (PMMA), also known as acrylic or acrylic glassas well as by the trade names Plexiglas, Acrylite, Lucite, and Perspexamong several others, is a transparent thermoplastic often used in sheetform as a lightweight or shatter-resistant alternative to glass. Thesame material can be utilized as a casting resin, in inks and coatings,and has many other uses.

Polycarbonates (PC) are a group of thermoplastic polymers containingcarbonate groups in their chemical structures. Polycarbonates used inengineering are strong, tough materials, and some grades are opticallytransparent. They are easily worked, molded, and thermoformed.

Polymers such as PMMA and PC can be made into a diffusing polymer in anumber of ways such as by adding light diffusing material such asself-reflecting particles to the polymers.

The broad concept of illuminating safety belt buckles is over 35 yearsold based on the patent literature. The challenges include packaging ofthe illuminator assembly within the buckle housing, energy managementand optical quality. The following is a summary of prior art approachesto illuminating the safety belt buckle, or the environs of the buckle.

Woodham—U.S. Pat. No. 9,151,485, issued Oct. 6, 2015. FIG. 2 of theWoodham discloses a buckle assembly configured to releasably interlockwith a seat belt tongue. The assembly includes a light emitting diode(LED) configured to emit a light when the seat belt tongue is notinterlocked with the assembly. An optional guide is positioned at leastpartially within a housing and composed of a substantially lighttransmitting material. The LED is positioned such that the light emittedby the LED passes through the optical guide.

Morinaga—U.S. Pat. No. 4,237,586, issued Dec. 9, 1980. FIGS. 10 and 15of Morinaga disclose an illuminated seat belt buckle with a lightemitting diode 307 whose light output is projected through a lightscattering lens 305i. See col. 7, 11. 36-39.

Brundidge—U.S. Pat. No. 4,365,285, issued Dec. 21, 1982. FIG. 3 ofBrundidge discloses a seat belt buckle assembly with a fiber opticdisplay 28 that is actuated by a switch 34 that toggles upon theengagement of the belt tongue with the buckle.

Eckmann—U.S. Pat. No. 4,933,818, issued Jun. 12, 1990. FIG. 3 of Eckmannis a cross-sectional view of a lighted buckle housing 10. A point oflight 15 and a light outlet 16 are both in the area of the buckleopening. A light emitting diode 18 is disposed in a lamp holder 17. Alight conducting path 19 is composed of several light guide segments 20,21 and 23, which branch off a tap 22 in the light-conducting path.

Schlaps—U.S. Pat. No. 9,434,348, issued Sep. 6, 2016. FIG. 1 of Schlapsdiscloses a seatbelt latch circuit that can include an illuminationsource configured to illuminate a seatbelt latch in response to asignal. The seatbelt latch circuit can also include a status sensorconfigured to output a first current if the seatbelt latch is in aremoved state, output a second current if the seatbelt latch is in aninserted state and output a third current if the seatbelt latch has afault. The seatbelt latch circuit communicates with a vehicle electricalsystem through only two conductors.

Kawamura—U.S. Pat. No. 5,132,880, issued Jul. 21, 1992. FIG. 1(diagrammatic) and FIG. 2 (schematic) of Kawamura disclose anilluminated seat belt buckle in which an optical fiber F transmits lightto an ejector 2 formed of a light-transmitting material such astransparent plastic.

Kawamura—U.S. Pat. No. 5,149,189, issued Sep. 22, 1992. FIGS. 1 and 2 ofKawamura illustrate a seat belt buckle 1 with a luminous cover section21. An LED is positioned within the buckle and below the luminous coversection 21.

Colvin—U.S. Pat. No. 5,181,773, issued Jan. 26, 1993. FIG. 6 of Colvinis a representative embodiment of an illuminated seat belt buckle inwhich an LED light source 52 is shrouded by a translucent cover portion38.

Kawamura—U.S. Pat. No. 5,176,439, issued Jan. 5, 1993. FIG. 1 ofKawamura discloses a seat belt buckle illuminated by LEDs 1 whose lightoutput is transmitted through a light guide 2 with total internalreflection. A V-shaped notch 2 d in portion 2 b of the light guide formsa reflecting prism. An ejector 20 is formed of a light-transmissivematerial, such as a clear polymeric material. A V-shaped recess 21formed within the ejector also functions as a prism to reflect and guidelight to the front of the ejector.

Collins et al—U.S. Pat. No. 5,438,492, issued Aug. 1, 1995. FIGS. 12 and13 of Collins et al are, respectively, plan and side elevational viewsof an illuminated seat belt buckle 22. An LED 200 is placed in a chamber202 within the buckle 22, and energized by wires routed from a plug-inconnector 214.

Blackburn et al—U.S. Pat. No. 5,892,436, issued Apr. 6, 1999. FIGS. 1and 5 of Blackburn et al illustrate a seat belt buckle illuminated byoptical fibers 72 emanating from a light source 70.

Blackburn et al—U.S. Pat. No. 5,944,135, issued Aug. 31, 1999. FIG. 2 ofBlackburn et al illustrates an illuminated seat belt buckle with a fieldeffect locking indicator.

Bergkessel—U.S. Pat. No. 6,102,440, issued Aug. 15, 2000. FIG. 2 ofBergkessel shows a seat belt system fitted with a compliance light 10and a buckle lock 24.

Griffin—US 2012/0089302, published Apr. 12, 2012. FIG. 1 of Griffindiscloses a seat belt system for a vehicle which may include a pluralityof seat belt assemblies each including a seat belt receptable, a lightsource for selectively illuminating the receptable, and a latchmechanism for releasably latching a seat belt buckle to the receptable.A controller may be operatively associated with the light source, thelatch mechanism sensor, a transmission gear position sensor, and atleast one of a door position sensor, engine sensor and air bag sensor.The controller may operably process signals received from the sensorsand direct the light source to selectively illuminate the seat beltreceptacle in various operational conditions of the vehicle.

Rogers et al—US 2001/0033492, published Oct. 25, 2001. FIG. 2 of Rogerset al illustrates an illuminated seat belt buckle in which anilluminator 54 transmits light through a U-shaped light pipe 62 to thebuckle opening.

Gray et al—US 2007/0236917, published Oct. 11, 2007. Gray et aldiscloses a lighted and heated seat belt buckle.

Knoedl—US 2014/0268844, published Sep. 18, 2014. Knoedl discloses anilluminated seat belt buckle. FIG. 2 is an exploded isometric view ofthe lighting device 26 that illuminates the insertion aperture of thebuckle.

Ellis et al—U.S. Pat. No. 6,558,027, issued May 6, 2003. FIG. 2 of Elliset al discloses a push button seat belt buckle with an illuminatedelectroluminescent panel.

Park—U.S. Pat. No. 7,275,613, issued Oct. 2, 2007. Park discloses anautomatic seat belt system that automatically unlocks if the ignitionkey is removed. A buckle lamp 20 is a secondary feature of the system.

Kohama—U.S. Pat. No. 7,360,794, issued Apr. 22, 2008. FIG. 2 of Kohama'794 illustrates the illumination portion of a lighted seat belt buckle.The illumination portion mounts an LED 53 in a holding board that isoriented generally transverse to the insertion direction of the belttongue, i.e. perpendicular in the FIG. 2 embodiment.

Kohama et al—U.S. Pat. No. 7,347,579, issued Mar. 25, 2008. FIG. 1 ofKohama et al illustrates a variation of the lighted seat belt buckle ofKohama above in which LEDs mounted on holding boards 49a project lightonto reflectors 52 embedded in the molded cover of the buckle.

Kohama—U.S. Pat. No. 7,569,265, issued Aug. 4, 2009. Kohama '265 usesthe same reflector-based design as FIG. 1 of Kohama et al above, butadds a “Light Intensity Control Device” in series with the LED circuitryto avoid an occurrence of unevenness of brightness. This is shownschematically in FIG. 2(b), where reference numeral 53 designates anLED.

Klick et al—U.S. Pat. No. 7,942,565, issued May 17, 2011. Klick et aldiscloses several embodiments of an optical waveguide for receivinglight from an LED and on the basis of total internal reflection changingthe main radiating direction of the electromagnetic light energy.

Line et al—U.S. Pat. No. 9,211,866, issued Dec. 15, 2015. Line et aldiscloses an illuminated seat belt buckle which is variously describedand claimed as illuminating the “vehicle interior,” or defining a“flashlight.”

Salter et al—U.S. Pat. No. 9,463,734, issued Oct. 11, 2016. Salter et aldiscloses an illuminated seatbelt assembly in which a “photoluminescentstructure” is disposed within a buckle and is configured to luminesce inresponse to excitation by a light source.

Schmotzer et al—U.S. Pat. No. 9,481,318, issued Nov. 1, 2016. Schmotzeret al discloses a seat belt buckle 10 incorporating a display 14.

As used herein, the term “sensor” is used to describe a circuit orassembly that includes a sensing element and other components. Inparticular, as used herein, the term “magnetic field sensor” is used todescribe a circuit or assembly that includes a magnetic field sensingelement and electronics coupled to the magnetic field sensing element.

As used herein, the term “magnetic field sensing element” is used todescribe a variety of electronic elements that can sense a magneticfield. The magnetic field sensing elements can be, but are not limitedto, Hall effect elements, magnetoresistance elements, ormagnettransistors. As is known, there are different types of Hall effectelements, for example, a planar Hall element, a vertical Hall element,and a circular vertical Hall (CVH) element. As is also known, there aredifferent types of magnetoresistance elements, for example, a giantmagnetoresistance (GMC) element, an anisotropic magnetoresistanceelement (AMR), a tunneling magnetoresistance (TMR) element, an Indianantimonide (InSb) sensor, and a magnetic tunnel junction (MTJ).

As is known, some of the above-described magnetic field sensing elementstend to have an axis of maximum sensitivity parallel to a substrate thatsupports the magnetic field sensing element, and others of theabove-described magnetic field sensing elements tend to have an axis ofmaximum sensitivity perpendicular to a substrate that supports themagnetic field sensing element. In particular, planar Hall elements tendto have axes of sensitivity perpendicular to a substrate, whilemagnetoresistance elements and vertical Hall elements (includingcircular vertical Hall (CVH) sensing element) tend to have axes ofsensitivity parallel to a substrate.

Magnetic field sensors are used in a variety of applications, including,but not limited to, an angle sensor that senses an angle of a directionof a magnetic field, a current sensor that senses a magnetic fieldgenerated by a current carried by a current-carrying conductor, amagnetic switch that senses the proximity of a ferromagnetic object, arotation detector that senses passing ferromagnetic articles, forexample, magnetic domains of a ring magnet, and a magnetic field sensorthat senses a magnetic field density of a magnetic field.

Despite the teachings of the above patent documents, there is still aneed for an easily and inexpensively manufactured assembly configured toform a light pattern proximate an opening slot of a safety belt bucklein a passenger compartment of a vehicle.

SUMMARY

The present invention addresses the design challenges of packaging,energy management and optical quality by providing an assembly that isboth space-efficient and energy-efficient.

An illuminable vehicle interior assembly is provided. The assemblyincludes a vehicle interior part having an opening between inner andouter surfaces of the part. The outer surface faces a passengercompartment of a vehicle. An illumination module is mounted to the innersurface of the part and includes a substrate, a light source supportedon the substrate to emit incoherent visible light rays through a lightemitting surface of the light source and a driver supported on thesubstrate to controllably supply electrical power to the light sourcebased on a command signal from a remote electronic control unit over avehicle bus. A lens is molded in a molding process to have a lighttransmissive output surface proximate the opening and a lighttransmissive input surface aligned with the light source. The lensgathers and receives the light rays at the input surface and redirectsgathered light rays to the output surface to generate light in a patternof substantially uniform intensity proximate the opening and into thepassenger compartment.

The lens maybe molded from a transparent optical-grade material. Thelens may be molded from an optical-grade material which causes the lightrays to emerge diffusely from the output surface. The substrate maycomprise a printed circuit board (PCB).

The assembly may further comprise a protective layer overlying andprotecting the driver and the substrate proximate the light source fromexternal moisture or foreign substances.

The protective layer may be an overmolding encapsulating the driver andthe substrate, but does not cover the light emitting surface of thelight source.

The assembly may further comprise flexible wiring including a pluralityof flexible conductors and insulation surrounding the flexibleconductors, the wiring configured to electrically connect the substrateto the remote electronic control unit over the bus.

The assembly may further comprise an opaque layer covering exteriorsurfaces of the lens, other than the input and output surfaces, to blocklight rays exiting from the lens except through the output surface.

The lens may include a first layer molded from a transparent opticalgrade material in the molding process and a second layer bonded to thefirst layer formed from an opaque material molded onto the first layerin the molding process.

The molding process may be an injection molding process such as amulti-shot molding process.

The substrate may comprise a printed circuit board (PCB) wherein thelight source may include a light emitting diode (LED) disposed on thePCB and connectable with the control unit via the driver

The output surface may be a class A surface.

The module may be snapped-into engagement with the part at the innersurface of the part.

An illuminable safety belt buckle assembly is provided. The assemblyincludes a safety belt buckle cover having an opening for receiving atongue. The opening extends between inner and outer surfaces of thecover. The outer surface faces a passenger compartment of a vehicle. Anillumination module is mounted to the inner surface of the cover andincludes a substrate, a light source supported on the substrate to emitincoherent visible light rays through a light emitting surface of thelight source and a driver supported on the substrate to controllablysupply electrical power to the light source based on a command signalfrom a remote electronic control unit over a vehicle bus. A lens ismolded in a molding process to have a light transmissive output surfaceproximate the opening and a light transmissive input surface alignedwith the light source. The lens gathers and receives the light rays atthe input surface and redirects gathered light rays to the outputsurface to generate light in a pattern of substantially uniformintensity proximate the opening and into the passenger compartment.

The lens may be molded from a transparent optical-grade material.

The lens may be molded from an optical-grade material which cause thelight rays to emerge diffusively from the output surface.

The substrate may comprise a printed circuit board (PCB).

The assembly may further comprise a protective layer overlying andprotecting the driver and the substrate proximate the light source fromexternal moisture or foreign substances.

The protective layer may be an overmolding encapsulating the driver andthe substrate, but does not cover the light emitting surface of thelight source.

The assembly may further comprise flexible wiring including a pluralityof flexible conductors and insulation surrounding the flexibleconductors. The wiring may be configured to electrically connect thesubstrate to the remote electronic control unit over the bus.

The assembly may further comprise an opaque layer covering exteriorsurfaces of the lens, other than the input and output surfaces, to blocklight rays exiting from the lens except through the output surface.

The lens may include a first layer molded from a transparent opticalgrade material in the molding process and a second layer bonded to thefirst layer and formed from an opaque material molded onto the firstlayer in the molding process.

The molding process may be an injection molding process such as amulti-shot molding process.

The substrate may comprise a printed circuit board (PCB) wherein thelight source may include a light emitting diode (LED) disposed on thePCB and connectable with the control unit via the driver.

The output surface may be a class A surface.

The module may be snapped-into engagement with the cover at the innersurface of the cover.

Other technical advantages will be readily apparent to one skilled inthe art from the following figures, descriptions and claims. Moreover,while specific advantages have been enumerated, various embodiments mayinclude all, some or none of the enumerated advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle seat fitted with a safety beltbuckle;

FIG. 2 is a perspective view of the safety belt buckle, removed from theseat, showing the placement of the light output surface of anilluminator assembly proximate the insertion slot for the belt tongue;

FIG. 3 is a schematic perspective view of the interior of the buckleshowing the illuminator assembly seated or snapped-into engagement withthe buckle housing;

FIG. 4 is a perspective view of the illuminator assembly removed fromthe buckle housing;

FIG. 5 is a perspective view of the illuminator lens which functions asa waveguide to route light rays emitted by a lamp such as an LED in agenerally orthogonal direction;

FIG. 6 is a schematic view of the layout of electronic componentsmounted on a printed circuit board (PCB) within the illuminatorassembly;

FIG. 7 is a schematic perspective view of another embodiment of theilluminator assembly; and

FIG. 8 is a view, similar to the view of FIG. 7, but from a differentangle.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

As used in this application, the term “substrate” refers to anynon-conductive, flexible, semi-flexible or rigid single or multi-layercomponent which mechanically supports and electrically connectselectronic components and which has one or more surfaces to which alayer or conformed coating is or can be applied hereto and theelectronic components by the methods described herein such as, withoutlimitation, polymers and other plastics, as well as composite materials.Furthermore, the shape of the substrate and particularly the surface(s)to be coated or layered can be any part of an assembly or devicemanufactured by any of various methods, such as, without limitation,conventional molding, extruding, or otherwise fabricated. One preferredapplication contemplated herein is the coating of substrates andsupported electronic components that are automotive components such asautomotive interior printed circuit boards and their supportedelectronic components.

A printed circuit board (PCB) populated with electronic components iscommonly called a printed circuit assembly (PCA), a printed circuitboard assembly or a PCB assembly (PCBA).

As used herein “potting” is a process of filling a complete electronicassembly with a sold or gelatinous compound for resistance to shock andvibration, and for exclusion of moisture and corrosive agents.Thermosetting plastics on silicone rubber gels are often used. Manysites recommend using silicone or epoxy to protect from impact and loosewires. In the potting process, an electronic assembly is placed inside amold which is then filled with an insulating liquid compound thathardens permanently protecting the assembly.

The term “overlies” and cognate terms such as “overlying” and the like,when referring to the relationship of one or a first, superjacent layerrelative to another or a second, subjacent layer, means that the firstlayer partially or completely lies over the second layer. The first,superjacent layer overlying the second, subjacent layer may or may notbe in contact with the subjacent layer; one or more additional layersmay be positioned between respective first and second, or superjacentand subjacent, layers.

With reference to FIG. 1, a conventional vehicle seat 10 is fitted witha safety belt buckle 12. The buckle 12 is adapted to latch and unlatchthe tongue 11 of a belt 13 with an internal mechanism (not shown).

FIG. 2 shows the safety belt buckle 12 separate from the vehicle seat.The buckle 12 has a housing formed by mating halves 14 and 16, whoseconnection defines a seam line 18. At the open end of the buckle 12 is aslot 20 for passage of the belt tongue 11. An output surface 22, i.e.,light-emitting surface of a waveguide lens, is proximate the slot 20.

FIG. 3 is a schematic perspective view of the bottom half 14 of thebuckle housing, separated from the top half. An illuminator assembly ormodule, indicated generally at 24, is seated (i.e. snapped-intoengagement with the buckle half 14) in a complementary-shapedcompartment in the housing member 14. The output surface 22 of awaveguide lens 28 is located at the open end of the housing member 14.

FIG. 4 shows the lens 28 of the illuminator assembly 24 separate fromthe buckle 12. The assembly 24 is preferably formed of a molded plasticbody 26 or cover layer as shown in FIG. 5 over a printed circuit board(PCB) 27 as shown in FIG. 6. A group of electrical leads 30 areconnected to the assembly 24. The leads 30 can be assigned to powersupply, ground, a local interconnect network (known as “LIN”,standardized as ISO/AWI 17987-8) and a Hall effect sensor to response tothe presence of the tongue 11 within the buckle 12 (two leads).

The waveguide lens 28 is shown fitted in the plastic body 26. Thelight-emitting class A surface 22 is proximate the slot 20 in the buckle12 for passage of the belt tongue 11 as best shown in FIGS. 2 and 3.

FIG. 4 shows the waveguide lens 28 separate from the illuminationassembly 24. An input surface 32 receives light rays emitted through thelight-emitting surface of a light source such as an LED 36 as show inFIG. 6. The waveguide lens 28 is configured to guide or direct theprojected light rays received at surface 32 by internal reflection tothe light-emitting output surface 22. The lens 28 may be formed of atransparent or light-diffusing optical-grade material such as PMMA(polymethyl methacrylate) or PC (polycarbonate) in a molding process. Ifa light-diffusing material is used, light rays emerge diffusely from theoutput surface 22. The other exterior surfaces of the first layer of thelens 28 are coated with an opaque color material layer 31 to contain anddirect the light rays and reflect/direct the light rays within the lens28. The layer 31 may be white in color and can be characterized as askin.

The second layer 31 of the lens 28 is bonded to the first layer of thelens 28 and is formed from a diffuse material molded onto the lens 28 inthe molding process.

The molding process is preferably an injection molding process such as amulti-shot molding process. Consequently, the lens 28 can becharacterized as a 2-shot, dual-molded lens.

As shown in FIGS. 7 and 8, second embodiment of a molded plastic coverlayer 26′ may be provided for the printed circuit board (PCB) 27 whichcarries the LED 36 and a driver 38 for the LED 36 and may be provided inthe same shot as the shot which provides the second layer 31. The PCE 27also carries varies other electronic components 40 such as capacitors,resistors, and diodes for enabling operation of the LED 36 and thedriver 38.

The cover layer 26′ may be a thermoplastic elastomer (TPE) which is aclass of polymers that behave like thermoset rubber but that, abovetheir melt or softening temperatures, are melt processable viathermoplastic processing methods and can be easily reprocessed andremolded. The ability to process these materials with thermoplasticmethods allows for design and fabrication freedom.

Bondable thermoplastic elastomer compounds may be formulated to providea chemical bond to plastic substrates, such as TPE substrates, makingpossible simpler part designs that are less dependent on mechanicalinterlocks or require time consuming surface preparation duringproduction.

These compounds are compatible with inert or multi-shot molding methodsand are ideal for applications where a “soft-touch” feature can providean ergonomic touch or enhance consumer appeal, dampen sound orvibration, or provide impact or shock protection. Also, such compoundsare elastic.

A thermoplastic elastomer (TPE) of at least one embodiment of thepresent invention may be selected from the group consisting of athermoplastic polyolefin, thermoplastic urethane, polyester,polycarbonate, acrylonitrile/butadiene/styrene (“ABS”), polypropylene,lomod, bexloy, mixture of acrylonitrile/butadiene/styrene (i.e., ABS)and polycarbonate, and mixtures thereof.

As noted above, the lens 28 is typically molded from a transparent,optical grade polymer such as clear PMMA or PC. Alternatively, the lens28 may be molded from a diffused or diffusing polymer such as PMMA or PCwith a light diffusing additive such as self-reflecting particles.

FIG. 6 is a schematic representation of electronic components of theilluminator assembly 24 shown in cooperative relationship. Thecomponents are mounted on a base 58 including a substrate or printedcircuit board (PCB) 38 which, in turn, supports and electricallyinterconnects the electrical components to form a printed circuit boardassembly (PCBA). A terminal set 30 is received by a terminal block 34supported on the printed circuit board 27. A side-emitting lightemitting diode (LED), schematically included at 36, emits light rayswhich are received at the input surface 32 of the waveguide lens 28. TheLED 36 is supported on the printed circuit board and is electricallyconnected to the LED driver also supported on the PCB 38. The waveguidelens 28 is configured to guide or direct the light rays to the outputsurface 22 in a direction generally orthogonal to the direction of thelight rays emitted by the LED 36. Alternatively, a top-emitting LED maybe fired directly into the lens 28 (i.e. optic) placed over the PCB 38.

The illuminator assembly 24 is suitable for use with an automobile,which can be any passenger vehicle used for land transportation, such asa car, minivan, truck, etc. According to alternative embodiments, theassembly 24 may be used with any type of vehicle, such as watervehicles, air vehicles, etc.

The illuminator assembly 24 may be electrically connected to a maincontroller of an electrical system of the vehicle. The main controlleris typically electrically connected to one or more switches and/or oneor more sensors so that the assembly 24 can be manually or automaticallyoperated to turn the assembly 24 “on” or “off”. For example, the maincontroller can be electrically connected to an ignition switch, a lightsensor, a headlight switch and/or an interior light switch as neededand/or desired.

The printed circuit board assembly (PCBA) may include the driver 38 orcontroller coupled to the main controller of the vehicle. The driver 38may comprise one or more analog and/or digital electrical or electroniccomponents, and may include a microprocessor, microcontroller,application-specific integrated circuit (ASIC), programmable logic,and/or other circuit elements. According to an exemplary embodiment, thedriver 38 may be configured to receive data via one or more electricalwires or buses such as the leads 30 from a plurality of automobilesystems within the automobile. For example, the driver 38 can beconfigured to receive data from sensors on an automobile. According tovarious exemplary embodiments, the printed circuit board 27 may be aflexible circuit board, a rigid circuit board, conductive foil, and/orother suitable form.

In one exemplary embodiment, the PCB assembly includes the LED driver 38having a power source and LED control circuitry to operate the LED 36.The LED driver 38 may be an LIN LED driver including a LIN transceiver,a LIN protocol/controller and a microcontroller (MCU).

The light source 36 may include an incandescent bulb, a fluorescentbulb, the light emitting diode (LED), a light pipe, anelectroluminescent device, a neon or argon bulb or fiber optics. Thelight source(s) may produce light of any color or from any portion ofthe light spectrum. In various exemplary embodiments, a light filter(not shown) may be placed between the light source 36 and the lens 28.

The ECU of the vehicle and the LED driver 38 or controller are typicallyconnected via a vehicle bus such as a local interconnect network (LIN orCAN) line or bus capable of two-way communications. LIN is one of manypossible in-vehicle local area network (LAN) communications protocols. Apower line and a ground line may be provided between the ECU and thecontroller 38 (via leads 30). The controller typically includes atransceiver interface within the MCU, a microprocessor and its controllogic within the MCU, the drive or driver, and an electrical powersource. The controller 38 may be integrated or physically coupled withthe LED 36 in the cover layer or housing 26 or 26′, while the ECU isprovided some distance away from the cover layer or housing 26 or 26′.

The power source or circuit of the controller 38 supplies electric powerof predetermined voltage levels to the MCU and the Hall Effect sensor(s)through the drive or driver 28. The transceiver within the MCU is acommunications interface circuit connected to the network or vehicle busfor communications and operates as a receiver section for the MCU and atransmitter section back to the ECU. The driver 38 typically includesthe driver circuit for driving the LED 36.

The Hall Effect sensor(s) are typically provided near or coupled to thehousing adjacent the opening 20 and may be driven to generate pulsesignals which are received by the MCU.

The MCU of the driver 38 typically includes a memory and may beconfigured as a conventional microcomputer including a CPU, a ROM, a RAMand the like or as a hardwired logic circuit.

The ECU and the controller 38 may perform data communications regularlythrough the LIN or CAN bus. In such data communications, the controlleror driver 38 may transmit state data indicating the state of the LED 36to the ECU.

The ECU and/or the controller 38 may confirm the desired state of theLED 36. The state of the ECU is based on various states detected bynon-contact position sensor(s), commands and the present state of theLED 36, to generate commands.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. An illuminable safety belt buckle assemblycomprising: a safety belt buckle cover having an opening for receiving atongue, the opening extending between inner and outer surfaces of thecover, the outer surface facing a passenger compartment of a vehicle; anillumination module mounted to the inner surface of the cover andincluding a substrate, a light source supported on the substrate to emitincoherent visible light rays, and a driver supported on the substrateto controllably supply electrical power to the light source based on acommand signal from a remote electronic control unit over a vehicle bus;and a waveguide lens having a light transmissive input surface orientedto receive the visible light rays emitted by the light source and routethe visible light rays to a light transmissive output surface orientedsubstantially orthogonally to the input surface, the waveguide lensgathering and receiving the light rays at the input surface andredirecting them by internal reflection to the output surface toilluminate the area proximate the outer surface.
 2. The assembly asclaimed in claim 1, wherein the waveguide lens comprises an integralbody injection molded from a transparent optical-grade plastic.
 3. Theassembly as claimed in claim 2, wherein the waveguide lens body ismolded from an optical-grade plastic which cause the light rays toemerge diffusively from the output surface.
 4. The assembly as claimedin claim 1, wherein the waveguide lens body has a coating of opticallyopaque material on its exterior exclusive of the input surface and theoutput surface.
 5. The assembly as claimed in claim 1, furthercomprising a protective layer overlying and protecting the driver andthe substrate proximate the light source from external moisture orforeign substances.
 6. The assembly as claimed in claim 5, wherein theprotective layer is an overmolding encapsulating the driver and thesubstrate, that does not cover the light source.
 7. The assembly asclaimed in claim 1, further wherein the light source is a side-emittinglight emitting diode.
 8. The assembly as claimed in claim 1, furthercomprising an opaque skin injection molded onto exterior surfaces of thewaveguide lens body, other than the input and output surfaces.
 9. Theassembly as claimed in claim 1, wherein the waveguide lens includes afirst layer injection molded from a transparent optical grade plastic inthe molding process and a second layer bonded to the first layer andformed from an opaque material molded onto the first layer in themolding process.
 10. The assembly as claimed in claim 9, wherein themolding process comprises a multi-shot injection molding process. 11.The assembly as claimed in claim 1, wherein the substrate comprises aprinted circuit board (PCB) and wherein the light source includes alight emitting diode (LED) disposed on the PCB and connectable with thecontrol unit via the driver.
 12. The assembly as claimed in claim 1,wherein the output surface is a class A surface.
 13. The assembly asclaimed in claim 1, wherein the module is snap-fittable-into engagementwith the cover at the inner surface of the cover.